Reinforcement Bar Support Device

ABSTRACT

A modular wire device to support and maintain the position of horizontal and vertical reinforcement bars in concrete masonry unit walls. Additionally, the device may function to provide structural support and to act as the base for attaching insulation, bricks or other veneers to a wall structure. The wire support device comprises a planar wire frame to be set within horizontal mortar joints, coupled with a plurality wire cross members. The wire cross members may have crimps and loops to precisely align horizontal and vertical reinforcement bars. Hingedly attached extension members may extend outward from the wire frame and the face of the wall to vertical wire surface material supports using end loops to provide support for insulation, brick or other veneers. The frame and horizontal bars provide additional structural reinforcement across the wall thickness.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.61/321,518 filed on Apr. 7, 2010, entitled “Rebar Support.”

FIELD OF THE INVENTION

The present invention relates to a wire device to aid in the positioningof reinforcement bar in concrete masonry unit walls, while providingadditional reinforcement through the thickness of the wall.

DESCRIPTION OF THE PRIOR ART

The present invention pertains to a modular wire reinforcement deviceused in concrete block construction. More particularly, the presentinvention is a device for the positioning of vertical and horizontalsteel reinforcement bars precisely where intended. The present inventionmay also be used to support and provide attachment points for bricks,insulation and other veneers on the surface of the concrete masonrywall. Typical wall installations include an outer veneer of brick orother material, a middle layer of insulation, followed by a structuralfoundation of concrete.

Concrete blocks and mortar have relatively little tensile strength, andit is therefore necessary to use steel reinforcing bars to support therequired tensile loads of a structure. Some of the bars extendvertically through the cavities in the concrete blocks, so as to anchorthe blocks to the concrete footing, and some extend horizontally alongthe planar mortar joints at various levels. The vertical reinforcementbars are particularly important, as they provide the tensile strengthcapability required for the wall given its design loads. Typical loadsmay include in-plane, shear and bending loads. Pressure on one face ofthe wall is also a consideration, especially for designs thatincorporate buried walls with soil applying pressure loads on one side.For the most economical design, an engineer will locate the rebar as faras possible from the neutral axis of the wall toward the tension side,while still allowing a certain minimum amount of space between the rebarand the inner surface of the block cavity to allow concrete grout toflow around the rebar so as to completely embed it.

In practice it is difficult to keep the vertical reinforcing bar at aprecise distance relative to the outer surface of the blocks along itsentire length as the grout is being poured. As a result, when the cavityis filled with concrete grout the bar may drift or bend away from theinner surface of the block toward the neutral axis of the wall, whereits tensile strength is underutilized. To compensate for uncertainty inthe actual location, engineers customarily use a knockdown factor forthe strength of the steel in their calculations, compensating for theuncertainty in its position as it is being installed. This results inthe use of oversized or unnecessary steel reinforcement bar members.Even when oversized steel reinforcing bars are specified, there is somedanger that the bars may become displaced far enough from their designlocation to make them relatively ineffective, resulting in overstressedmasonry. Additionally, specifying oversized reinforcing bars isexpensive and adds greatly to the cost of construction.

Patents have been granted, as well as applications published, to severaldevices that attempt to address the problems at hand. However, the priorart fails to provide an easy-to-use device or system which aligns bothhorizontal and vertical reinforcement bars, while additionally providingsupport for both the wall itself and any additional surface attachmentsthat may be installed.

Lampus U.S. Pat. No. 4,034,529 is directed to a rebar bolster device forsolid grouted walls. A solid, grouted wall is formed of layers of blockwith spaces being formed within the block or between blocks toaccommodate rebar and concrete. A rebar support device comprising twoparallel and laterally spaced longitudinally extending rods and aplurality of cross rod members positioned therebetween are positioned onthe face shells of the block so the cross rod members extend in theaforementioned spaces. Additionally, this device contains one or twotroughs to allow horizontal placement of reinforcement bar. Further, itcan be used to assist in the alignment of vertical reinforcement bars.The Lampus invention, however, fails to provide a way to precisely alignvertical reinforcement bars and does not support or suggest a solutionto the issue of securing surface attachments to the wall. The presentinvention provides for both, in addition to providing for the precisealignment of horizontal reinforcement bar.

LeGrady U.S. Pat. No. 4,107,895 is directed to a reinforcing barlocating means adapted for disposition in a mortar layer between coursesof concrete blocks; the reinforcing bar locating means made of a singlewire and comprising a generally S-shaped intermediate to be imbedded inmortar between courses of concrete blocks. The LaGrady inventionrequires the wire devices to be cast and embedded within the blocks.This provides a far less versatile and inefficient method ofreinforcement bar alignment.

Several other patents exist in the art that require individualcomponents to be fixed to or cast within concrete blocks. Tudek U.S.Pat. No. 4,337,605 is directed to a generally rectangular concretebuilding block of partially hollow construction with at least one largerectangular vertical opening extending therethrough and provided with agenerally zigzag shaped rod embedded in the interior walls and extendingtransversely of and formed with a transverse loop in the center of eachhollow interior. Wheeler U.S. Pat. No. 4,748,785 is directed to aresilient support member for reinforcing steel having first and secondlegs separated by an open cavity and being normally axially aligned inthe inoperative position of the support member. Swenson U.S. Pat. No.5,896,722 is directed to a weldless spacer for manually connectingwithout a tool two reinforcement cage wires or re-bars of a concretereinforcing structure in spaced-apart relation is a unitary resilientwire member. The present invention may be used with any concrete block,without the need for specialty casting, and does not require that eachor any block be customized.

Hampton U.S. Pat. No. 4,190,999 is directed to a fixture for preciselylocating the vertical reinforcing steel bars in a hollow block wall atthe exact positions specified. The fixture forms a horizontal supportingstructure that is adapted to be laid on the top surfaces of the blocksat various levels. Additionally, the fixture has cross wires havingcircular rings with downwardly projecting legs that extend down into thecavities of the hollow blocks and engage the inner surfaces. The ringsare positioned in vertical alignment with respect to one another,allowing the alignment of vertical reinforcement bar. While attending tothe issue of vertical reinforcement bar placement, the Hampton patentfails to account for support of horizontal or external surface supportbars.

Uehara U.S. Pat. No. 4,318,262 is directed to a bar-positioning membercomprising a long metal wire or wire rod with at least one indentationto receive a metal bar. The indentation is formed by bending part of thewire and it has only one opening, which opens along the longitudinaldirection of the wire. The Uehara patent describes a significantly moredifficult system to implement. Additionally, the bar positioning memberserves to place bars on in a single plane. In particular, the Ueharadevice is designed to create a larger planar surface structure, moresuitable to an expanse of cement than a wall or vertical structure.

Dressler U.S. Pat. No. 6,141,937 is directed toward avertical-rebar-support system has a ring base oriented horizontallyintermediate side walls of a concrete foundational excavation. The Tatuminvention serves only to support the base and vertical reinforcementbars within the foundation, thus failing to address the need forvertical supports at higher points in the wall, horizontal reinforcementbars or external surface veneer supports.

The present invention addresses the issues of positioning bothhorizontal and vertical reinforcement bars, as well as providingadditional support for external additions to the wall such as bricks orinsulation. These prior art devices have several known drawbacks.Several of the prior art inventions address the placement of horizontalreinforcement bars, vertical reinforcement bars or both. None of theaforementioned prior art addresses both while providing stability foradditions to the wall. Further, none of the prior art devices contains amethod or manner of securing both horizontal and vertical reinforcementbars in specific and precise locations. Further, the present inventioneliminates the need for specialty cement block to accommodate thealignment structure or the addition of a support structure to eachindividual cement block. The present invention addresses all of theseissues in one modular device and system, providing an efficient, costeffective mechanism of support and alignment in the construction ofcement masonry walls.

SUMMARY OF THE INVENTION

In view of the foregoing disadvantages inherent in the known types ofreinforcement bar placement systems now present in the prior art, thepresent invention provides a new device and system wherein the same canbe utilized for providing convenience for the user when placing andmaintaining the position of steel reinforcement bar during theconstruction of concrete masonry unit walls.

The primary purpose of the present invention is to provide means forpositively placing and maintaining vertical and horizontal reinforcingbars at the precise positions in a concrete masonry wall. The presentinvention assures an engineer that reinforcement bar will remain at anintended location at all times, and its full tensile strength capabilitywill be utilized. When installing a new wall, masons currently have torely on thick concrete and good timing to ensure the reinforcement baris held vertically inside the block wall or horizontally during thegrouting process. This can be a difficult task, especially in high-liftgrout applications. Mistakes during construction may necessitateexpensive and time consuming corrections, which can result in higherproject costs. If the individual or crew constructing the wall decidesnot to correct the positioning of the reinforcement bar, the integrityof the finished product may become compromised and potentially result infuture structural problems. A device is needed that assists in thealignment and installation of reinforcement bar. The present inventionfulfills this need.

The present invention maintains reinforcement bar placement by means ofcontinuous, ladder-like assembly modules placed in the horizontal planarmortar joints of the wall at specified levels as the wall is built. Thepresent invention is designed to locate the vertical and horizontalreinforcing bars at precise locations specified by the design. This wiredevice aids in the positioning of rebar in concrete masonry unit wallswhile providing additional reinforcement across the thickness of a wall.The device is comprised of a planar wire frame with numerousperpendicular crimped wires designed to hold vertical and horizontalrebar. It is especially useful in high-lift grout applications and alsoprovides additional structural support for the completed wall orbuilding. Masons, construction crews and other individuals can use thisdevice to save time and reduce labor costs when building new walls.Increased through-thickness strength is also obtained as out of planedeflection of the masonry and shear loads across it thickness arereinforced by the device, the horizontal rebar and frame provideadditional tensile support and prevent the wall from expanding outwardor bending out of plane. This increased structural support furtherprevents the wall from splitting across the mortar joints under load.

It is therefore an object of the present invention to provide anefficient, cost effective manner of placing and maintaining thelocations of vertical and horizontal reinforcement bars in cement andmortar wall or structure.

A further aspect of the present invention is that it may be used tosecure anchor foam, brick, and other veneers to structural andrefractory walls using horizontal frame extension members that arehingedly attached to the base frame. The Horizontal extension membersterminate with a loop that engages vertical wire that aids in theplacement of external materials to the wall, such as insulation, bricksor other veneers.

Other objects, features and advantages of the present invention willbecome apparent from the following detailed description taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTIONS OF THE DRAWINGS

FIG. 1 is a perspective view of the present invention supportinghorizontal and vertical reinforcement bars.

FIG. 2 is a perspective view depicting the device installed on a blockwall.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides masons, construction crews, and otherindividuals with a modular reinforcement bar positioning system for usein concrete masonry unit walls. This device may be comprised of amodular, planar frame that holds a plurality of cross members, creatinga design that is similar in appearance to a ladder. The gauge andmaterial of the frame and cross members may be any suitable or desirableto one skilled in the art, include 9-gauge steel wire. Said crossmembers may be crimped for holding a horizontal rebar at preciselocations or bent into circles for securing around a verticalreinforcement bar at a precise location. Each cross member may be spotwelded at its ends to the frame. In use, the device may be placed alongthe length of the block wall in a horizontal mortar joint allowingindividuals to securely place vertical and horizontal rebar in thecorrect positions within the blocks. Multiple modules of the device canbe placed at varying levels to provide alignment and support of thecement block and mortar structure. Dimensions may vary in accordancewith the length and width of the wall section being constructed. Methodsof constructions, methods of use and other specifications may vary uponmanufacturing. The invention may be produced or tailored to modules ofvarying lengths, allowing for flexibility in placement.

Hingedly attached horizontal extension members from the wire frameextend outward to support vertical support bars for insulation orbuilding veneers. The extension members terminate with a closed loop,which is engaged by the vertical support bars to maintain its position.Relative vertical movement between the outer veneer and the foundationis isolated by the use of a hinge, which is particularly useful inearthquake prone areas. The two structures can float relative to oneanother, eliminating internal loads build-up caused by shifts inposition.

Referring now to FIG. 1, there is shown a perspective view of thepresent invention supporting horizontal and vertical reinforcement bars14, 16 set into a block wall 20. The present invention comprises arectangular wire reinforcement frame 11, to which one or a plurality ofwire cross members 12 is affixed. Said wire cross members 12 may havecrimped wire loops 13 through which vertical reinforcement bars 14 arealigned. Additionally, said wire cross members 12 may have one or aplurality of central crimps 15 through which one or a plurality ofhorizontal reinforcement bars 16 may be positioned. Further, horizontalextension members 22 may extend beyond the wire frame 11 on either side.Extension members 22 of said wire frame 11 are hingedly attached to theframe to allow relative vertical displacement between the end of theextension member 23 and the wire frame 11. External vertical supportbars support and align external bricks 18 and/or insulation or otherveneers. The horizontal extension member 22 are hinged 21 to thevertical support wires 17 to accommodate relative movement between theveneer 18 and the cement block wall 20. The extension member 22terminates with a closed loop to accept the vertical support bars.

Referring now to FIG. 2, there is shown a perspective view depicting thedevice installed on a block wall 20. The present invention comprises arectangular wire reinforcement frame 11, to which one or a plurality ofwire cross members 12 is affixed. Said wire cross members 12 may havecrimped wire loops 13 through which vertical reinforcement bars 14 maybe aligned. Additionally, said wire cross members 12 may have one or aplurality of central crimps 15 through which one or a plurality ofhorizontal reinforcement bars 16 may be positioned. Hingedly attachedextension members 22 of said wire crossbars extend beyond therectangular wire bar frame 11 to locate vertical support wires 17 forthe support and alignment of and external brick wall 18 or insulation19. The extension members 22 are hingedly 21 attached to the verticalsupport wires 17.

With respect to the above description, it is to be realized that theoptimum dimensional relationships for the parts of the invention, toinclude variations in size, materials, shape, form, function and mannerof operation, assembly and use, are deemed readily apparent and obviousto one skilled in the art, and all equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of theprinciples of the invention. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described, and accordingly, all suitable modifications andequivalents may be resorted to, falling within the scope of theinvention.

1) A modular wire device for positioning and supporting a pluralityreinforcement bars, comprising: a planar wire frame positioned withinhorizontal mortar joints of a wall; said planar wire frame having one ora plurality of wire cross members; said wire cross members having crimpsto engage and precisely align horizontal reinforcement bars; and saidwire cross members having loops to engage and precisely align verticalreinforcement bars. 2) The device as in claim 1, further comprisingextension members extending horizontally from said wire frame andterminating with a closed loop to engage veneer vertical support wires.3) The device as in claim 2, wherein said extension members hingedlyattach to said wire frame. 4) A modular wire device for positioning andsupporting a plurality reinforcement bars, comprising: a planar wireframe positioned within horizontal mortar joints of a wall; said planarwire frame having one or a plurality of perpendicular wire crossmembers; said wire cross members having crimps to engage and preciselyalign horizontal reinforcement bars; and said wire cross members havingloops to engage and precisely align vertical reinforcement bars; andextension members horizontally extending from said wire frame andterminating with a closed loop to engage veneer vertical support wires.5) The device as in claim 4, wherein said extension members hingedlyattach to wire frame. 6) A method of aligning reinforcement barscomprising the steps of: employing a planar wire frame to fit withinhorizontal planar mortar joints of a cement wall; attaching one or aplurality of wire cross members to said planar wire frame; crimping saidwire cross members to precisely align horizontal reinforcement bars;looping said wire cross members to precisely align verticalreinforcement bars. 7) A method as in claim 6, further comprising thesteps of: aligning veneer vertical support wires with hingedly attachedextension members from said wire frame.